PRODUCT CAMPAIGN: INCORRECT EMISSION SYSTEM. Chevrolet Nova 1986

For 1990-2009 cars

# PRODUCT CAMPAIGN: INCORRECT EMISSION SYSTEM

#### Model and Year: 1986-1987 CHEVROLET NOVA

General Motors has determined that a small number of 1986-87 Chevrolet Nova model vehicles were incorrectly distributed. Some vehicles equipped with Federal emission systems were distributed in California and some vehicles equipped with California emission systems were distributed in states other than California. This condition could cause an involved vehicle to fail a state mandated emission test.

To correct this condition, the emissions system must be inspected, and if it is the incorrect type for the state in which the vehicle is licensed registered, it must be changed to the correct type.

#### VEHICLES INVOLVED

Involved are certain 1986-87 Chevrolet Nova model vehicles produced within the following VIN breakpoints:

#### MODEL/YEAR PLANT FROM THROUGH ---------- ----- ---- ------- 1986 Nova Fremont GZ246796 GZ318744 1987 Nova Fremont HZOO1014 HZO22991

#### NOTE: A total of 115 units with Federal emissions were distributed in California and 21 units with California emissions were distributed in states other than California.

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

#### OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of Owner Letter included with this bulletin).

#### DEALER CAMPAIGN RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into new or used vehicle inventory, or it is in your dealership for service in the future you should take the steps necessary to be sure the campaign correction has been made be ore reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

#### PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." with no special instruction code, but on an advise code (2).

#### For a California to Federal conversion, the following parts are required:

Quantity/ Part Number Description Vehicle ----------- ----------- ------- 94845211 Fitting Kit - Exhaust Emission Control California To Federal................................1

94841560 Exhaust pipe - Intermediate (Fed.)...................1

94841555 Catalytic Converter Air Inlet Pipe (Fed.)............1

#### For a Federal to California conversion, the following parts are required:

Quantity/ Part Number Description Vehicle ----------- ----------- ------- 94845212 Fitting Kit - Exhaust Emission Control Federal to California................................1

94841562 Exhaust Pipe - Intermediate (Calif./Canadian).........1

There are only enough kits available at GMSPO to correct the vehicles involved (115 units requiring kit P/N 94845212 and 21 units requiring kit P/N 94845211). To prevent over ordering, it will be necessary to provide the VIN of the vehicle requiring the kit when ordering. Only one kit for each VIN will be shipped.

The kits consist of the following parts (order kit P/N's only - do not order individual parts):

Qty. Fed. to Cal. Description Cal. to Fed. Qty. --- ----------- ----------- ----------- --- 1 94845212 Fitting Kit - Exhaust 94845211 1 Emission Control --- -------- -------------------------------- -------- - 1 94844323 Air Cleaner Assy. (W/Element) 94840262 1 N/A Hose - Manifold Air Inj. #2 94843422 1 2 94842711 Clamp-Hose Type E clsd. Dia. M31 94842711 4 N/A Clamp-Converter Air Inlet Pipe No GM P/N 1 N/A Bolt-Hex (M8X1.25X35) Hdr. Pt. 94842268 1 N/A Bolt-Ctltc. Conv. Air Inlet Pipe 94843110 1 N/A Clamp-Ctltc. Conv. Air Inlet Pipe 94841557 1 N/A Bolt-Hex. (M6X1.25X1O.5) Self Lock 94843540 2 N/A Pipe-Air Inj. 94840284 1 1 94840218 Pipe Asm. - Air Inj. (Manifold Asm.) N/A 1 94844589 Hose-Air Inj. Pipe to Air Cleaner 94840285 1 N/A Plug-Exhaust Manifold 94842692 1 1 94843898 Computer Asm. Exh. Emiss. Control 94843897 1 N/A Valve Asm.-Alt. Com ensator W/Brkt 94843957 1 N/A Bolt-Hex (M6X1.OX14) Hdr. Pt. 94842305 1 1 94843927 Pipe Asm. - Exh. Emiss. Vac. 94843926 1 N/A Valve-Exh. Emiss. Cont. Chk. 94840219 1 1 94843956 Hose-Vacuum (Length =300 mm) 94843956 1 N/A Hose-Vac. Pipe to Dist. Cont. #2 94843424 1 2 94842678 Plug-Dist. Vac. Cont. N/A 1 94840206 Gasket-Carb. Heat Insulator #1 94840206 1 2 94840205 Gasket-Carb. Heat Insulator #2 94840205 2 1 94840211 Gasket-EGR Valve Adapter 94840211 1 2 94842630 Gasket-EGR Valve Pipe (1987) 94842630 2 2 No GM P/N Gasket-EGR Valve Pipe (1986) No GM P/N 2 1 94844512 Label-Emiss. Control Info. (1987) 94844511 1 1 94844328 Plate-Eng. Vac. Hose Info. Wl P/S 94843929 1 1 94844327 Plate-Eng. Vac. Hose Info. W/0 P/S N/A 1 94844507 Converter-Ctltc. 94841506 1 1 94841553 Gasket-Exh. Pipe to Conv. 94841553 1 1 94841561 Gasket-Exh. Pipe-Center to Conv. 94841561 1 1 94840602 Gasket-Exh. Pipe to Exh. Manifold 94840206 1

#### SERVICE PROCEDURE

1. Determine which emission system is installed on vehicle by inspecting vehicle emission control infomation label on underside of engine hood panel.

2. Determine need for correction by following steps described in Figure 1.

Following appropriate Service Manual procedures, unless specified otherwise, perform the following:

#### FOR FEDERAL TO CALIFORNIA CONVERSION

3. Remove carburetor.

4. Remove high altitude compensation (HAC) valve, hose, jet (6-way vacuum hose connector - green) and bracket.

5. Remove vacuum pipe assembly.

6. Remove EGR pipe and EGR valve.

7. Remove AIR suction pipes, hoses and blank plug exhaust manifold side.

8. Install new AIR suction system parts from kit, see Figure 3.

9. Install new EGR valve and EGR pipe and gasket from kit.

10. Install new vacuum pipe assembly from kit. Torque retaining bolt to 25 Nm (18 lb. ft.)

11. Install Carburetor.

12. Connect vacuum hoses to carburetor and vacuum pipe assembly - see vacuum hose infomation label applicable to vehicle, also reference appropriate Service Manual component diagrams in section 6El4.

13. Install blank plugs to vacuum pipes at carburetor and distributor vacuum advancer unit per California hose information label.

14. Install new air cleaner from kit.

15. Attach appropriate Emission Control Information and Vacuum Hose Information labels from kit.

#### Note: There are two (2) different vacuum hose labels - one each for "with power steering" identified by '4A-LC W/PS' at top left corner and "no power steering" identified by '4A-LC' at top left corner.

16. Remove catalytic converter, gaskets and exhaust pipe-center.

17. Install new exhaust pipe-center and gasket, new catalytic converter and gaskets from kit.

18. Remove ECM and install new ECM from kit.

19. Install Campaign Identification Label.

#### FOR CALIFORNIA TO FEDERAL CONVERSION

3. Remove carburetor.

4. Remove blank plugs from carburetor vacuum port (front of carburetor) and from distributor vacuum advancer unit - shown on underhood vacuum hose information label. (Cal.).

5. Remove vacuum pipe assembly.

6. Remove EGR pipe and EGR valve.

7. Remove AIR suction pipes and hoses, unfasten pipe union at exhaust manifold side and unfasten pipe clamp. Install plug (part of kit) into exhaust manifold AIR suction pipe hole.

8. Install new AIR suction system parts from kit, see Figure 2 - Do not connect to catalytic converter.

9. Install new EGR valve and EGR pipe and gasket from kit.

10. Install new vacuum pipe assembly from kit. Torque retaining bolt to 25 Nm (18 lb. ft.).

11. Install Carburetor.

12. Install new HAC valve from kit - includes hose, bracket, and jet (6-way vacuum hose connector - green).

13. Connect vacuum hoses to carburetor and vacuum pipe assembly - see vacuum hose information label applicable to vehicle, also reference appropriate Service Manual component diagrams in section 6EI4.

14. Install new air cleaner from kit.

15. Attach appropriate Emission Control Infomation and Vacuum Hose Information labels from kit.

16. Remove catalytic converter, gaskets and exhaust pipe-center.

17. Install new exhaust pipe-center and gasket, new catalytic converter and gaskets from kit. Connect new AIR suction pipe to converter.

18. Remove ECM and install new ECM from kit.

19. Install Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL (Figure 4)

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign bulletin will require a "Campaign Identification Label". Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.

Apply "Campaign Identification Label" only on a clean dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* FAILED PARTS LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS ---------------- -- -------- ----- -- -- --- --- Inspect For Emission 00 V4480 0.2 0.1 System Type - No Further Action Required

Convert Emission System 2 94845212 ** 00 V4481 2.6 0.1 From Federal To California

Convert Emission System 3 94845211 ** 00 V4482 2.6 0.1 From California To Federal

* Campaign Administrative Allowance

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

(Notification Used By Chevrolet Motor Division)

Dear Chevrolet Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that a small number of 1986-87 Chevrolet Nova model vehicles were incorrectly distributed. Some vehicles equipped with Federal emission systems were distributed in California and some vehicles equipped with California emission systems were distributed in states other than California. This condition could cause your vehicle to fail a state mandated emission test.

WHAT WE WILL DO

To correct this condition, your vehicles emission system must be inspected, and if it is the incorrect type for the state in which the vehicle is licensed/registered, it must be changed to the correct type. This inspection/correction will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this inspection/ correction have been sent to your dealer. The labor time necessary to inspect your vehicle is approximately 10 minutes. If your emission system must be changed, an additional 2 1/2 hours will be required. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.